Part 3

Engine













Disassembly

111. Remove the bolt and the coolant inlet port.
- Remove and discard the O-ring seal.





112. NOTE: Mark the location of the front cover fasteners prior to removing them.

Remove the 10 bolts and the engine front cover.





113. NOTICE: Sealant is used where the upper and lower crankcase meet. Failure to cut the sealant may result in pulling the lower crankcase seal out while removing the front cover gasket.

Use a thin-blade scraper to cut the sealant where the upper and lower crankcase meet.

- Remove and discard the front cover gasket.





114. Remove the 10 bolts and the flexplate or flywheel.
- Discard the bolts.





115. NOTICE: Use extreme care when removing the flywheel front adapter to prevent damage to the alignment dowel pin.

If equipped, remove the flywheel front adapter.





116. NOTICE: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear.

NOTICE: Drill only deep enough to penetrate the seal. Engine damage will occur if the seal is drilled too deep.

Using a center punch, mark a location for 2 holes 180 degrees apart, 9.53 mm (0.37 in) from the outer diameter of the crankshaft flange. Using a drill bit of the appropriate size for the slide hammer being used, drill a hole on each side of the crankshaft rear seal as shown. Drill the holes to a depth of 8.76 mm (0.34 in) to capture the metal case of the crankshaft seal as well as the wear ring.





117. Using the 2 drilled holes, the Slide Hammer and a commercially available body dent puller attachment, walk the seal out of the rear cover by alternating from side to side to remove the crankshaft rear seal.
- Discard the crankshaft rear seal.





118. Clean and inspect the crankshaft sealing surface.





119. NOTICE: To prevent engine damage, replace damaged or missing dowel pins before installing the engine rear cover.

NOTE: Manual transmission shown, automatic transmission similar.

Remove the bolts from the engine rear cover.

1. For all vehicles, remove the 8 bolts.

2. For manual transmission vehicles, remove the 3 additional bolts.





120. NOTICE: Sealant is used where the upper and lower crankcase meet. Failure to cut the sealant may result in pulling the lower crankcase seal out while removing the rear cover.

NOTE: A 139.7 mm (5.5 in) long thin-blade scraper is needed to correctly cut the sealant.

Use a thin-blade scraper to cut the sealant where the upper and lower crankcase meet.





121. NOTICE: Sealant is used where the upper and lower crankcase meet. Failure to cut the sealant may result in pulling the lower crankcase seal out while removing the rear cover.

NOTE: A 139.7 mm (5.5 in) long thin-blade scraper is needed to correctly cut the sealant.

Use a thin-blade scraper to cut the sealant where the upper and lower crankcase meet. Remove the rear engine cover.

- Remove and discard the press-in-place gasket.

- Clean and inspect the sealing surfaces.





122. Remove the retaining nut for the oil level indicator and tube.





123. Remove the bolt. Remove the oil level indicator and tube.
- Remove and discard the O-ring seal.





124. NOTICE: Do not disconnect the glow plug electrical connectors before dislodging the seals from the valve cover or the wiring harness may be damaged.

NOTE: Only one glow plug connector shown.

Using an appropriate tool, dislodge the glow plug seal from the valve cover and disconnect the retainers.





125. Disconnect the glow plug electrical connectors by pulling on the glow plug wiring harness tee (above the seal at each glow plug) and remove the glow plug harness.

126. Remove the 4 retaining nuts and the LH valve cover bracket with the EP sensor and tube assembly.





127. Disconnect the crankcase vent oil separator tube at the crankcase.





128. Remove the nut, 2 bolts and the crankcase vent oil separator tube.





129. NOTE: RH shown, LH similar.

NOTE: Mark the location of the stud bolts.

Remove the 4 stud bolts, 6 bolts and valve covers.

- Remove and discard the press-in-place gaskets.

- Clean and inspect the sealing surfaces.





130. NOTE: If engine coolant is found in the combustion chambers, it may be necessary to install a new glow plug sleeve.

Remove the 8 glow plugs.





131. NOTE: The Fuel Rail Pressure (FRP) sensor is located on the RH fuel rail.

Disconnect the FRP sensor electrical connector.





132. Using the Fuel Injector Connector Disconnect Tool, disconnect the fuel injector electrical connectors. Detach the fuel charging wiring harness from the fuel rail.





133. NOTE: The terminals in the fuel charging harness plug are not serviced, install a new fuel charging harness if damaged.

Remove the 2 fuel charging harness electrical connectors from the valve cover base and remove the fuel charging harness.





134. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.

NOTE: Use a back-up wrench on the fuel injector fittings.

Remove and discard the 8 fuel injector supply tubes.





135. NOTE: RH shown, LH similar.

Remove the 4 bolts and the high-pressure fuel rails.





136. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.

137. NOTICE: Failure to account for all snap rings or pieces of snap rings prior to placing the vehicle back in service may cause engine damage. A missing snap ring can be ingested into the lube oil system causing severe engine damage.

NOTICE: To prevent engine damage, do not use air tools to remove the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.

NOTICE: Failure to use the Injector Cups and the Fuel Injector Holding Rack may result in damage to the fuel injector.

NOTE: There is no need to drain the fuel rail.

NOTE: If engine coolant is found in the combustion chambers, it may be necessary to install a new injector sleeve.

Remove the bolt, the fuel injector hold down and the fuel injector.
- Remove and discard the O-ring seal and soft steel washer.

- Place the fuel injector in the fuel injector holding rack.





138. NOTE: If a snap ring or piece of a snap ring is missing from the injector hold-down assembly, it must be located prior to removing the shop towels.

Remove the shop towels.

139. NOTE: Mark the location of the rocker arm assemblies prior to removing.

Remove the 16 bolts and the rocker arm assemblies.





140. Remove the 2 rocker arm spacer bars.





141. NOTE: Mark the location of the valve bridges before removing.

Remove the 16 valve bridges.





142. NOTICE: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.

Mark the location and remove the 16 push rods.





143. Remove the 22 bolts and the valve cover bases.
- Remove and discard the press-in-place gasket.

- Clean and inspect the sealing surfaces.





144. If necessary, remove and discard the high-pressure fuel rail seal.





145. NOTE: Left cylinder head shown, right cylinder head similar.

Remove and discard the 10 head bolts from each cylinder head.





146. Remove the 5 outer bolts from each cylinder head.





147. Using the Cylinder Head Lifting Bracket, remove the cylinder heads.





148. Check for cylinder head distortion. For additional information, refer to Cylinder Head Distortion Cylinder Head Distortion.

149. Remove and discard the 2 cylinder head gaskets.





150. Remove and discard the 4 cylinder head dowel sleeves.





151. Check for cylinder block distortion. For additional information, refer to Cylinder Block Distortion Cylinder Block Distortion.

152. NOTICE: To prevent engine damage, keep the valve tappets in the order in which they were removed. Install all valve tappets back in their original positions.

Remove the 4 bolts and the valve tappet guides. Remove the valve tappets.





153. NOTE: Mark the locations of the 5 longer bolts to aid in installation.

Remove the 22 bolts and oil pan.





154. Remove the 2 bolts and oil pump screen and pickup tube.
- Remove and discard the O-ring seal.





155. Remove the 9 bolts and upper oil pan.
- Remove and discard the press-in-place gasket for the upper and lower oil pan.

- Clean and inspect the sealing surfaces.





156. NOTE: Prior to removing any piston and connecting rod assemblies, it is recommended that piston protrusion be evaluated. This will help identify bent or twisted connecting rods.

Install the Dial Indicator Gauge with Holding Fixture. Check the piston protrusion above the crankcase as follows.

- Zero the Dial Indicator Gauge with Holding Fixture on the crankcase deck surface.

- Position the Dial Indicator Gauge tip on the piston head at the 3 or 9 o'clock position.

- Rotate the crankshaft to measure the maximum piston protrusion and record.

- Reposition the Dial Indicator Gauge tip onto the piston head at the opposite position.

- Rotate the crankshaft to measure the maximum piston protrusion and record.

- Average the 2 readings. If the average reading is lower than the specification, the piston is lower in the bore than it should be. This indicates a bent or twisted connecting rod.





157. Using a Feeler Gauge Set, check for connecting rod side clearance.





158. NOTE: Only one connecting rod cap shown.

Remove the 2 bolts and the connecting rod caps.





159. NOTICE: If evident from the top of the cylinder bore, remove the carbon ridge prior to removing the rod and piston assemblies. This reduces the chance of piston ring land damage during removal.

Use a razor knife or emery board to scrape the carbon ridge from the top of the cylinder bore.

160. Using a wood or plastic hammer handle, push the connecting rod and piston assembly out of the cylinder bore.





161. Remove and discard the piston rings.

1. Remove the keystone ring.

2. Remove the intermediate compression ring.

3. Remove the oil control ring.





162. Remove and discard the connecting rod bearings.





163. Install the Dial Indicator Gauge with Holding Fixture and measure the camshaft gear backlash. Install a new camshaft assembly if backlash is not within specification.





164. Install the Dial Indicator Gauge with Holding Fixture and measure the camshaft end play. Install a new camshaft assembly if end play is not within specification.





165. NOTICE: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear.

Install the Dial Indicator Gauge with Holding Fixture and measure the crankshaft end play. Record the end play.





166. Remove the bolt and the CKP sensor.





167. Remove the bolt and the CMP sensor.





168. Remove the block heater.





169. Remove the 20 lower crankcase main bearing bolts. Remove the lower crankcase assembly.





170. Remove and discard the lower crankcase seals and the crankshaft lower bearings.





171. Using the appropriate lifting device, remove the crankshaft assembly.





172. Remove and discard the 4 crankshaft upper bearings and crankshaft upper thrust bearing.





173. NOTICE: Do not nick or scratch the camshaft bearings with the camshaft lobes or engine damage will occur.

Remove the 2 thrust plate mounting bolts and remove the camshaft and gear assembly.





174. NOTICE: This patch bolt is unique. Do not substitute or engine damage may occur.

Remove the 8 bolts and the 8 piston cooling tubes.





175. Using the Camshaft Service Set, remove and discard the camshaft bearings.